May 2024 Volume 6

EQUIPMENT & TECHNOLOGY

Features and Benefits of the Mitsubishi AZ600 The AZ600 has a unique Mitsubishi welding head optimized for the DED process. The head accurately feeds wire feedstock into the focus point of the laser beam. Meanwhile, the entire process is shielded by inert gas flowing through the nozzle. The laser power source is derived from the super-reliable fiber laser used on Mitsubi shi’s industry-leading metal cutting laser systems. The wire feedstock can easily be changed in minutes right on the front of the system. Mitsubishi’s experience with wire handling in their industry-leading wire EDM machines is evident when the system quickly straightens and feeds the wire to the welding head. The entire system is super vised by a control and drive system designed and manufactured by Mitsubishi Electric. All these proven systems are combined in a reliable, user friendly and state-of-the-art metal additive manufac turing system. Many metal additive manufacturing processes, including DED, build parts on a baseplate. One of the post-processing steps is to remove the parts from the baseplate. Mitsubishi’s wire EDM machines are the industry standard for accurately separating parts from baseplates productively and reliably. Both wire and sinker EDM machines can be used to create accurate tool surfaces when building forging dies. The combination of addi tive manufacturing and EDM processes can accelerate die making and repair.

AZ600 welding capability with narrow head configuration Forging blanks: This additive system can build forging blanks that are the same material, size, and shape as the production blank. While the process is not fast enough for high-volume production, it can make a handful of parts quickly to prove a process. Producing prototypes: Additive manufacturing can also be used to make prototypes before forging dies are created. The prototypes can be made of the proper material and approach the integrity of a forged part with some post-processing, like machining and heat treating. One example is a connecting rod built by the applications team at MC Machinery Systems, to show the capability of the AZ600. MC Machinery, a subsidiary of Mitsubishi Electric, is the North American supplier and servicer of Mitsubishi fabrication and EDM equipment.

Rick Neff is an industry consultant in additive manufacturing technology. He has his own consulting business in Cincinnati, Ohio. Phone: 513-808-7073 Email: rick@rickneffllc.com

John Petti is Additive Manufacturing Product Manager at MC Machinery in Elk Grove Village, IL. Phone: 630-616-2917 Email: john.petti@mcmachinery.com

3D-printed connecting rod, as built, machined on the baseplate and finish machined

To show the practical application of the AZ600, MC Machinery conducted an exercise to make a traditionally forged part, a connecting rod. The AZ600 printed the connecting rod in 5 hours and 34 minutes using 17-4PH steel. It was machined on the baseplate and then removed from the baseplate using wire EDM. The baseplate side was then machined. This required about 2 hours on the EDM and about 2 hours total CNC machine time.

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